ACS A0570882 User manual

Brand: ACS

Model: A0570882

Type: User manual

15, 30, & 60 cfm

Compact Dehumidifying Dryers

Part Number: A0570882

Bulletin Number: SM1-690.1

Effective: 8/05/04

Write Down Your Serial Numbers Here For Future Reference:

_________________________ _________________________

We are committed to a continuing program of product improvement.

Specifications, appearance, and dimensions described in this manual are subject to change without notice.

DCN No. ____________

15, 30, & 60 cfm Compact Dryers ii

Shipping Information

Unpacking and Inspection

You should inspect your dryer for possible shipping damage.

Thoroughly check the equipment for any damage that might have occurred in transit, such as

broken or loose wiring and components, loose hardware and mounting screws, etc.

In the Event of Shipping Damage

According to the contract terms and conditions of the Carrier, the responsibility of the

Shipper ends at the time and place of shipment.

Notify the transportation company’s local agent if you discover damage.

Hold the damaged goods and packing material for the examining agent’s inspection. Do not

return any goods before the transportation company’s inspection and authorization.

File a claim with the transportation company. Substantiate the claim by referring to the

agent’s report. A certified copy of our invoice is available upon request. The original Bill of

Lading is attached to our original invoice. If the shipment was prepaid, write us for a

receipted transportation bill.

Advise customer service regarding your wish for assistance and to obtain an RMA (return

material authorization) number.

If the Shipment is Not Complete

Check the packing list as back-ordered items are noted on it. You should have:

˛ Dehumidifying Dryer

˛ Bill of lading

˛ Packing list

˛ Operating and Installation packet

˛ Electrical schematic and panel layout drawings

˛ Component instruction manuals

Re-inspect the container and packing material to see if you missed any smaller items during

unpacking.

If the Shipment is Not Correct

If the shipment is not what you ordered, contact the shipping department immediately. For

shipments in the United States and Canada, call 1 (414) 354-0970; for all other countries, call

our international desk at (414) 354-0970. Have the order number and item number available.

Hold the items until you receive shipping instructions.

Returns

Do not return any damaged or incorrect items until you receive shipping instructions from the

shipping department.

15, 30, & 60 cfm Compact Dryers iii

Credit Returns

Prior to the return of any material authorization must be given by the manufacturer. A

RMA number will be assigned for the equipment to be returned.

Reason for requesting the return must be given.

ALL returned material purchased from the manufacturer returned is subject to 15% ($75.00

minimum) restocking charge.

ALL returns are to be shipped prepaid.

The invoice number and date or purchase order number and date must be supplied.

No credit will be issued for material that is not within the manufacturer’s warranty period

and/or in new and unused condition, suitable for resale.

Warranty Returns

Prior to the return of any material, authorization must be given by the manufacturer. A

RMA number will be assigned for the equipment to be returned.

Reason for requesting the return must be given.

All returns are to be shipped prepaid.

The invoice number and date or purchase order number and date must be supplied.

After inspecting the material, a replacement or credit will be given, at the manufacturer’s

discretion. If the item is found to be defective in materials or workmanship, and it was

manufactured by our company, purchased components are covered under their specific

warranty terms.

15, 30, & 60 cfm Compact Dryers iv

Table of Contents

CHAPTER 1: SAFETY.................................................................... 6

1-1 How to Use This Manual ............................................................................................ 6

Safety Symbols Used in this Manual.....................................................................6

Dryer Safety Tags ................................................................................................7

1-2 Warnings and Precautions ......................................................................................... 7

1-3 Responsibility............................................................................................................. 8

General Responsibility..........................................................................................8

Operator Responsibility ........................................................................................9

Maintenance Responsibility ................................................................................10

Reporting a Safety Defect...................................................................................10

1-4 Technical Specifications........................................................................................... 11

Annex B Information...........................................................................................11

CHAPTER 2: FUNCTIONAL DESCRIPTION .............................. 12

2-1 Models Covered in This Manual ............................................................................... 12

2-2 General Description ................................................................................................. 12

What is desiccant? .............................................................................................13

The Process/Regeneration Cycle .......................................................................13

2-3 Standard Features ................................................................................................... 13

Mechanical Features ..........................................................................................13

Electrical Features .............................................................................................13

Controller Features.............................................................................................13

2-4 Options .................................................................................................................... 14

2-5 Safety Devices and Interlocks .................................................................................. 14

CHAPTER 3: INSTALLATION ..................................................... 16

3-1 Uncrating the Equipment.......................................................................................... 16

3-2 Rigging and Placing the Dryer.................................................................................. 16

Recommended Dryer Lifting Hardware ...............................................................17

3-3 Electrical Connections.............................................................................................. 18

3-4 Setup Procedures .................................................................................................... 19

Checking for Proper Blower Rotation..................................................................19

Making Dryer/Drying Hopper Process Air Connections .......................................19

Drying Hopper Air Trap Considerations...............................................................20

Optional Aftercooler............................................................................................20

3-5 Initial Start-up........................................................................................................... 20

Pre-Startup Checks............................................................................................20

Starting Up the Dryer..........................................................................................21

Auto-Tuning the Dryer ........................................................................................21

Shutting Down the Dryer ....................................................................................21

CHAPTER 4: OPERATION .......................................................... 22

4-1 Start-up.................................................................................................................... 22

4-2 Controller Description and Operation........................................................................ 23

15, 30, & 60 cfm Compact Dryers v

Identifying Control Panel Indicator Lights and Switches for the Standard

Controller ...........................................................................................................23

Process Air Temperature Controller....................................................................24

Setting the Process Air Temperature ..................................................................25

Restoring the Process Air Temperature Controller (E5CN) to Factory Settings....26

Process Air Dew Point Display ...........................................................................29

Setting the High Dew Point Alarm.......................................................................29

Restoring the Process Air Dew Point Meter (E5CK) to Factory Setup..................29

4-3 Dryer Operation Procedures..................................................................................... 30

Controller Operation ...........................................................................................30

Alarm Display Messages ....................................................................................32

4-4 Auto-Tuning the Dryer.............................................................................................. 33

4-5 Shutting Down the Dryer .......................................................................................... 33

CHAPTER 5: MAINTENANCE..................................................... 34

5-1 Preventative Maintenance Schedule......................................................................... 34

5-2 Preventative Maintenance........................................................................................ 35

Servicing Process Air Filters...............................................................................35

Servicing the Dew Point Monitor.........................................................................36

5-3 Corrective Maintenance ........................................................................................... 37

Symptoms of Worn Desiccant.............................................................................37

Replacing Worn Desiccant .................................................................................38

Replacing the Process/Regeneration Heater ......................................................40

Replacing/Cleaning the Regeneration Cooling Coils ...........................................41

CHAPTER 6: TROUBLESHOOTING........................................... 42

6-1 Introduction.............................................................................................................. 42

6-2 Determining Temperature Controller Errors or Sensor Errors.................................... 45

Using a Thermocouple .......................................................................................45

Using a Platinum Resistance Thermometer ........................................................45

CHAPTER 7: APPENDIX ............................................................. 46

7-1 Warranty.................................................................................................................. 46

Warranty Specifications..........................................Error! Bookmark not defined.

Warranty Restrictions .............................................Error! Bookmark not defined.

Warranty Liabilities.................................................Error! Bookmark not defined.

Customer Responsibilities ......................................Error! Bookmark not defined.

7-2 Drawings and Diagrams ........................................................................................... 47

Aftercooler Design Specifications .......................................................................48

Spare Parts List.................................................................................................................. 50

7-4 Dryer Identification (Serial Number) Tag................................................................... 51

7-5 Technical Assistance ............................................................................................... 51

Parts Department ...............................................................................................51

Service Department............................................................................................51

Sales Department ..............................................................................................51

Contract Department ..........................................................................................51

15, 30, & 60 cfm Compact Dryers Chapter 1: Safety 6 of 51

Chapter 1: Safety

1-1 How to Use This Manual

Use this manual as a guide and reference for installing, operating, and maintaining your

dehumidifying dryer. The purpose is to assist you in applying efficient, proven techniques

that enhance equipment productivity.

This manual covers only light corrective maintenance. No other maintenance should be

undertaken without first contacting a service engineer.

The Functional Description section outlines models covered, standard features, and safety

features. Additional sections within the manual provide instructions for installation, pre-

operational procedures, operation, preventive maintenance, and corrective maintenance.

The Installation chapter includes required data for receiving, unpacking, inspecting, and setup

of the dehumidifying dryer. We can also provide the assistance of a factory-trained technician

to help train your operator(s) for a nominal charge. This section includes instructions, checks,

and adjustments that should be followed before commencing with operation of the

dehumidifying dryer. These instructions are intended to supplement standard shop

procedures performed at shift, daily, and weekly intervals.

The Operation chapter includes a description of electrical and mechanical controls, in

addition to information for operating the dryer safely and efficiently.

The Maintenance chapter is intended to serve as a source of detailed assembly and

disassembly instructions for those areas of the equipment requiring service. Preventive

maintenance sections are included to ensure that your dehumidifying dryer provides

excellent, long service.

The Troubleshooting chapter serves as a guide for identification of most common problems.

Potential problems are listed, along with possible causes and related solutions.

The Appendix contains technical specifications, drawings, schematics, parts lists, and

available options. A spare parts list with part numbers specific to your machine is provided

with your shipping paperwork package. Refer to this section for a listing of spare parts for

purchase. Have your serial number and model number ready when ordering.

Safety Symbols Used in this Manual

The following safety alert symbols are used to alert you to potential personal injury hazards.

Obey all safety messages that follow these symbols to avoid possible injury or death.

DANGER! DANGER indicates an imminently hazardous situation that, if not avoided,

will result in death or serious injury.

WARNING! WARNING indicates a potentially hazardous situation or practice that, if

not avoided, could result in death or serious injury.

Caution! CAUTION indicates a potentially hazardous situation or practice that, if

not avoided, may result in minor or moderate injury or in property damage.

15, 30, & 60 cfm Compact Dryers Chapter 1: Safety 7 of 51

Dryer Safety Tags

Hot! Read Operation

and Installation

Manual

High Voltage Earth Ground

Inside Enclosure

PE Protected Earth

Lifting Point Ground

1-2 Warnings and Precautions

Our equipment is designed to provide safe and reliable operation when installed and operated

within design specifications, following national and local safety codes. This may include, but

is not limited to OSHA, NEC, CSA, SPI, and any other local, national and international

regulations.

To avoid possible personal injury or equipment damage when installing, operating, or

maintaining this equipment, use good judgment and follow these safe practices:

˛ Read and follow these operation and installation instructions when installing,

operating, and maintaining this equipment. If these instructions become

damaged or unreadable, additional copies are available from the manufacturer.

˛ Follow all SAFETY CODES.

˛ Wear SAFETY GLASSES and WORK GLOVES.

˛ Work only with approved tools and devices.

˛ Disconnect and/or lock out power before servicing or maintaining the equipment.

˛ Use care when LOADING, UNLOADING, RIGGING, or MOVING this

equipment.

˛ Operate this equipment within design specifications.

˛ OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.

You should remove the fuses and carry them with you.

˛ Make sure the equipment and components are properly GROUNDED before you

switch on power.

˛ Use EXTEREME CAUTION when working with dryer. HIGH HEAT can be

dangerous. Keep body parts, tools, clothing, and debris away from dryer.

15, 30, & 60 cfm Compact Dryers Chapter 1: Safety 8 of 51

˛ When welding or brazing in or around this equipment, make sure VENTILATION is

ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with

sheet metal. An approved FIRE EXTINGUISHER should be close at hand and

ready for use if needed.

˛ Do not restore power until you remove all tools, test equipment, etc., and the

equipment and related components are fully reassembled.

˛ Only PROPERLY TRAINED personnel familiar with the information in this

manual should work on this equipment.

We have long recognized the importance of safety and have designed and manufactured our

equipment with operator safety as a prime consideration. We expect you, as a user, to abide

by the foregoing recommendations in order to make operator safety a reality.

1-3 Responsibility

These machines are constructed for maximum operator safety when used under standard

operating conditions and when recommended instructions are followed in the maintenance

and operation of the machine.

All personnel engaged in the use of the machine should become familiar with its operation as

described in this manual.

Proper operation of the machine promotes safety for the operator and all workers in its

vicinity.

Each individual must take responsibility for observing the prescribed safety rules as outlined.

All warning and danger signs must be observed and obeyed. All actual or potential danger

areas must be reported to your immediate supervisor.

General Responsibility

No mater who you are, safety is important. Owners, operators and maintenance personnel

must realize that every day, safety is a vital part of their jobs.

If your main concern is loss of productivity, remember that production is always affected in a

negative way following an accident. The following are some of the ways that accidents can

affect your production:

• Loss of a skilled operator (temporarily or permanently)

• Breakdown of shop morale

• Costly damage to equipment

• Downtime

An effective safety program is responsible and economically sound.

Organize a safety committee or group, and hold regular meetings. Promote this group from

the management level. Through this group, the safety program can be continually reviewed,

maintained, and improved. Keep minutes or a record of the meetings.

Hold daily equipment inspections in addition to regular maintenance checks. You will keep

your equipment safe for production and exhibit your commitment to safety.

Please read and use this manual as a guide to equipment safety. This manual contains safety

warnings throughout, specific to each function and point of operation.

15, 30, & 60 cfm Compact Dryers Chapter 1: Safety 9 of 51

Operator Responsibility

The operator’s responsibility does not end with efficient production. The operator usually has

the most daily contact with the equipment and intimately knows its capabilities and

limitations.

Plant and personnel safety is sometimes forgotten in the desire to meet incentive rates, or

through a casual attitude toward machinery formed over a period of months or years. Your

employer probably has established a set of safety rules in your workplace. Those rules, this

manual, or any other safety information will not keep you from being injured while operating

your equipment.

Learn and always use safe operation. Cooperate with co-workers to promote safe practices.

Immediately report any potentially dangerous situation to your supervisor or appropriate

person.

REMEMBER:

• NEVER place your hands or any part of your body in any dangerous location.

• NEVER operate, service, or adjust the dryer without appropriate training and first

reading and understanding this manual.

• NEVER try to pull material out of the dryer with your hands while it is running!

• Before you start the dryer check the following:

• Remove all tools from the dryer;

• Be sure no objects (tools, nuts, bolts, clamps, bars) are laying in the

hopper area;

• If your dryer has been inoperative or unattended, check all settings before starting the

unit.

• At the beginning of your shift and after breaks, verify that the controls and other

auxiliary equipment are functioning properly.

• Keep all safety guards in place and in good repair. NEVER attempt to bypass, modify,

or remove safety guards. Such alteration is not only unsafe, but will void the warranty

on your equipment.

• When changing control settings to perform a different mode of operation, be sure

selector switches are correctly positioned. Locking selector switches should only be

adjusted by authorized personnel and the keys removed after setting.

• Report the following occurrences IMMEDIATELY:

• unsafe operation or condition

• unusual dryer action

• leakage

• improper maintenance

• NEVER stand or sit where you could slip or stumble into the dryer

while working on it.

• DO NOT wear loose clothing or jewelry, which can be caught while working on a

dryer. In addition, cover or tie back long hair.

15, 30, & 60 cfm Compact Dryers Chapter 1: Safety 10 of 51

• Clean the dryer and surrounding area DAILY, and inspect the machine for loose,

missing or broken parts.

• Shut off power to the dryer when it is not in use. Turn the switch to the OFF position,

or unplug it from the power source.

Maintenance Responsibility

Proper maintenance is essential to safety. If you are a maintenance worker, you must make

safety a priority to effectively repair and maintain equipment.

Before removing, adjusting, or replacing parts on a machine, remember to turn off all electric

supplies and all accessory equipment at the machine, and disconnect and lockout electrical

power. Attach warning tags to the disconnect switch.

When you need to perform maintenance or repair work on a dryer above floor level, use a

solid platform or a hydraulic elevator. If there is a permanently installed catwalk on your

dryer, use it. The work platform should have secure footing and a place for tools and parts.

DO NOT climb on dryers, machines, or work from ladders.

If you need to repair a large component, use appropriate handling equipment. Before you use

handling equipment (portable “A” frames, electric boom trucks, fork trucks, overhead cranes)

be sure the load does not exceed the capacity of the handling equipment or cause it to become

unstable.

Carefully test the condition of lifting cables, chains, ropes, slings, and hooks before using

them to lift a load.

Be sure that all non-current carrying parts are correctly connected to earth ground with an

electrical conductor that complies with current codes. Install in accordance with national and

local codes.

When you have completed the repair or maintenance procedure, check your work and remove

your tools, rigging, and handling equipment.

Do not restore power to the dryer until all persons are clear of the area. DO NOT start and

run the dryer until you are sure all parts are functioning correctly.

BEFORE you turn the dryer over to the operator for production, verify all dryer enclosure

panels, guards and safety devices are in place and functioning properly.

Reporting a Safety Defect

If you believe that your equipment has a defect that could cause injury, you should

immediately discontinue its use and inform the manufacturer.

The principle factors that can result in injury are failure to follow proper operating procedures

(i.e. lockout/tagout), or failure to maintain a clean and safe working environment.

15, 30, & 60 cfm Compact Dryers Chapter 1: Safety 11 of 51

1-4 Technical Specifications

Annex B Information

The following design information is provided for your reference:

1. No modifications are allowed to this equipment that could alter the CE compliance

2. Ambient temperature: 0 degrees Celsius – Maximum (104 degrees Fahrenheit)

3. Humidity range: 50% relative humidity

4. Altitude: Sea level

5. Environment: Clean, dust-free and non-explosive

6. Radiation: None

7. Vibration: Minimal, i.e. machine mounting

8. Allowable voltage fluctuation: +/- 10%

9. Allowable frequency fluctuation: Continuous +/- 1%

Intermittent +/- 2%

10. Nominal supply voltage: 115/1/60 (Verify on serial number tag)

11. Earth ground type: TN (system has one point directly earthed through a protective

conductor)

12. Power supply should include a ground connection.

13. Over-current protection is supplied in the dryer, but additional protection should be

supplied by the user.

14. The door-mounted disconnect serves as the electrical disconnect device for 3 phase

units.

15. Dryer is not equipped with local lighting.

16. Functional identification

17. Dryer is supplied with an operating manual in the language of the destination

country.

18. Cable support may be required for power cord, depending on final installation.

19. No one is required to be in the interior of the electrical enclosure during the normal

operation of the unit. Only skilled electricians should be inside the enclosure for

maintenance.

20. Doors can be opened with a screwdriver, but no keys are required.

21. Two-hand control is not required or provided.

22. All dryers should be moved around and set in a place with a lift truck or equivalent.

23. There are no frequent repetitive cycles that require manual controlærepetitive

functions are automatic while the dryer is operating.

24. An inspection report detailing the functional test is included with the dryer.

25. The machine is not equipped with cableless controls.

26. Color-coded (harmonized) power cord is sufficient for proper installation.

15, 30, & 60 cfm Compact Dryers Chapter 2: Functional Description 12 of 51

Chapter 2: Functional Description

2-1 Models Covered in This Manual

This manual provides operation, installation, and maintenance instructions for 15, 30, and 60

cfm dehumidifying dryers. Model numbers are listed on the serial tag. Make sure you know

the model and serial number of your equipment before contacting the manufacturer for parts

or service.

Our dehumidifying mini dryers are designed to generate heated dehumidified air at carefully

controlled temperatures for use in plastic drying systems. Drying systems are sized to meet

the specific requirements stated by the Customer at the time of purchase.

2-2 General Description

Dehumidifying dryers are used to generate very low dew point air heated to a controlled

temperature for drying plastic pellets and regrind.

Our dryers force hot, dry air through resin in a drying hopper, where air picks up moisture

from the material and draws it back to the dryer. In the dryer, a desiccant bed strips moisture

from the air. The dried process air is then re-heated and delivered back into the drying

hopper for more moisture removal.

A small amount of ambient air is introduced into the process air stream to make up for the air

lost during the bed regeneration. Because the process air is typically much drier than the

ambient air, the air mixture maintains drying efficiency at a consistently high level. To

compensate for the humidity content in the air, this dryer is supplied with the proper amount

of desiccant.

Figure 1: Typical Dryer Air Flow Schematic

Drying

Hopper

Filter

(Separates Dust )

High Pressure

Peripheral Blower

Regeneration

Make Up Air

Moisture

Exhaust

15, 30, & 60 cfm Compact Dryers Chapter 2: Functional Description 13 of 51

What is desiccant?

Desiccant is a material that attracts and holds (absorbs) water from the air. The desiccant our

dryers use is a synthetic crystalline metal aluminosilicate blended with a clay binder and

formed into beads.

Absorbed water is driven from saturated desiccant by heating it to a high temperature

(reducing desiccant capacity to hold water) and forcing air through it. This moisture removal

process is called regeneration.

The Process/Regeneration Cycle

Our dryers have two desiccant beds. While one bed is on-line in the process air loop, the

other is off-line, being regenerated.

When a desiccant bed is on-line, it absorbs moisture from the process air. In time, the bed

becomes saturated with moisture and needs to be regenerated. The dryer automatically

redirects the process airflow to the second bed, and starts the regeneration cycle on the first

bed.

During regeneration, the dryer system heats air and forces it through the desiccant bed. The

moisture driven off the bed bleeds to the atmosphere.

2-3 Standard Features

Mechanical Features

• Dual desiccant beds

• Electrically-actuated air valve

• 13X Molecular Sieve

• Single regenerative process blower

• Drying temperature range of 180ºF to 250ºF.

Electrical Features

• Process thermocouple to be connected to drying hopper air inlet.

• Nema 12 control enclosure

• NFPA79 machinery electrical standards

• Non-fused electrical disconnect

• Branch fusing

• Mercury process heater contactor

• Regeneration temperature control

• Process high temperature alarm light

• Process/regeneration heater box

• High temperature safety system (Process/Regeneration)

Controller Features

• Mitsubishi programmable relay controller

15, 30, & 60 cfm Compact Dryers Chapter 2: Functional Description 14 of 51

• Display of process temperature set point and actual settings

2-4 Options

Options marked with “*” indicate options that can be factory installed or retrofitted in the

field.

• Process temperature up to 400ºF (or below 180ºF), including aftercooler on back of

dryer and silicone insulated delivery hose.

Note: For below 160°F, cooler needs to be outside, between dryer and

drying hopper.

• Machine mount adapter to accommodate a dryer and corresponding hopper.

• Drawer magnet, stainless steel construction.

• Casters, two (2) fixed and two (2) swivel.

• Portable carts

• Dew point monitor

• High temperature operation up to 400ºF

• Insulated process air delivery hose

2-5 Safety Devices and Interlocks

This section includes information on safety devices and procedures that are inherent to the

Dryer. This manual is not intended to supersede or alter safety standards established by the

user of this equipment. Instead, the material contained in this section is recommended to

supplement these procedures in order to provide a safer working environment.

At the completion of this section, the operator and maintenance personnel will be able to do

the following:

• Identify and locate specific safety devices.

• Understand the proper use of the safety devices provided.

• Describe the function of the safety device.

Safety Circuit Standards

Safety circuits used in industrial systems protect the operator and maintenance personnel

from dangerous energy. They also provide a means of locking out or isolating the energy for

servicing equipment.

Various agencies have contributed to the establishment of safety standards that apply to the

design and manufacture of automated equipment. The Occupational Safety and Health

Administration (OSHA) and the Joint Industrial council (JIC) are just a few of the

organizations that have joined with the plastics industry to develop safety standards.

Every effort has been made to incorporate these standards into the design of the dryer;

however, it is the responsibility of the personnel operating and maintaining the equipment to

familiarize themselves with the safety procedures and the proper use of any safety devices.

Fail Safe Operation

If a safety device or circuit should fail, the design must be such that the failure causes a

“Safe” condition. As an example, a safety switch must be a normally open switch. The switch

15, 30, & 60 cfm Compact Dryers Chapter 2: Functional Description 15 of 51

must be held closed with the device it is to protect. If the switch fails, it will go to the open

condition, tripping out the safety circuit.

At no time should the safety device fail and allow the operation to continue. For

example, if a safety switch is guarding a motor, and the safety switch fails, the motor should

not be able to run.

Safety Device Lock-Outs

Some safety devices disconnect electrical energy from a circuit. The safety devices that are

used on these dryers are primarily concerned with electrical power disconnection and the

disabling of moving parts that may need to be accessed during the normal operation of the

machine.

Some of the safety devices utilize a manual activator. This is the method of initiating the

safety lock out. This may be in the form of a plug, lever or a handle. Within this lockable

handle, there may be a location for a padlock. Personnel servicing the equipment should

place a padlock in the lockout handle.

In addition to the safety devices listed above, these dryers are equipped with a line cord plug.

This allows the operator or maintenance personnel to unplug the dryer from its power source

and tag it out. The plug can then be tagged with any number of approved electrical lockout

tags available at most electrical supply stores.

WARNING! Always disconnect and lockout all electrical power and pneumatic (i.e. compressed air)

sources prior to servicing or cleaning the dryer. Failure to do so may result in serious

injury. No one but the person who installed the lockout may remove it.

15, 30, & 60 cfm Compact Dryers Chapter 3: Installation 16 of 51

Chapter 3: Installation

3-1 Uncrating the Equipment

Dehumidifying Dryers are shipped mounted on a skid, enclosed in a plastic wrapper, and

contained in a cardboard box.

1. Pry the crating away from the skid.

Note: Remove the nails holding the box to the skid and lift the box

off carefully; avoiding staples in the 1’ x 4’ wood supports.

Cut the steel banding.

2. Use a pry bar to remove the blocks securing the unit to the skid.

3. Lift unit from sides. Use a pry bar if necessary to carefully remove the

skid from the unit.

4. Lower slowly.

3-2 Rigging and Placing the Dryer

Take care when rigging and placing the dryer. Figures 1, 2 and 3 on the following pages show

a suggested safe rigging diagram. It lets you lift the dryer/hopper unit vertically for

installation on the machine throat. Adjust chain lengths at the center sling bracket before you

lift the unit. Your dryer has built-in lifting lugs.

Caution! If you are mounting a machine-mount dryer with a magnet or transition adaptor on the

machine throat, you must provide additional support to hold the dryer securely on the

machine.

Be aware that off-center static and dynamic hopper loading can occur with machine

vibration. Again, provide additional support to hold the dryer securely on the machine.

Use caution and observe safety rules when lifting and placing your dryer!

15, 30, & 60 cfm Compact Dryers Chapter 3: Installation 17 of 51

Figure 2: Suggested Lift Rigging for Cart Mounted Dryers

Caution! Do not use a hoist to move or rig your Dryer when it is mounted on a cart!

Moving the Dryer with a hoist will cause it to become unstable and may

cause damage to the Dryer and/or injury to personnel!

Recommended Dryer Lifting Hardware

Item

Quantity

Description

Vendor

Vendor part no.

Adjustable alloy chain sling

McMaster-Carr

33665T32

Existing hopper lifting bracket

—

Drop forged steel eye nut

McMaster-Carr

3019T15

Chain connector

McMaster-Carr

3712T23

Figure 3: Suggested Lift Rigging for Floor Mounted Dryers

Note: Floor Mounted Dryers can be lifted by hoist or fork lift.

PROCESS

TEMPERATURE

DEW POINT

CONTROL

POWER

OFF

ALARM

POWER ON

OFF

PROCESS

TEMPERATURE

DEW POINT

CONTROL

POWER

OFF

ALARM

POWER ON

OFF

15, 30, & 60 cfm Compact Dryers Chapter 3: Installation 18 of 51

Figure 4: Suggested Lift Rigging for Machine Mounted Dryers

Caution! When using a hoist to move a machine mounted dryer, ALWAYS attach

chains to the three (3) locations/lifting points on the unit! Moving the

Dryer without the chains attached to all of the lifting points will cause the

unit to become unstable and may cause damage to the Dryer and/or injury

to personnel!

3-3 Electrical Connections

When making electrical connections to your dryer, ensure that you take into consideration

and make arrangements for the following:

• A qualified electrician should make all electrical connections.

• Fulfill all national, state, and local safety and electrical code requirements.

• The serial tag lists voltage, phase, and amp draw information:

• Line voltage must be within plus or minus ten percent (±10%) of the

voltage listed on the serial tag, or damage may occur. Phase imbalance

must be less than two percent (2%).

• Connect main power to the dryer at the disconnect or terminals in the upper right

corner of the control enclosure.

• Install a fused disconnect with a lockout feature in the power main leading to the dryer.

• The power drop must include a ground wire.

• Make sure all electrical connections are tight.

PROCESS

TEMPERATUR

DEW POINT

CONT

ROL

POWE

OFF

ALAR

POWER ON

OFF

15, 30, & 60 cfm Compact Dryers Chapter 3: Installation 19 of 51

3-4 Setup Procedures

This section provides the procedures necessary for configuring your Dehumidifying Dryer.

Configuration of your dryer includes checking for proper blower rotation, making

dryer/drying hopper process air connections and the optional aftercooler (on 15 and 30 cfm

models). We recommend that you carry out these procedures in the order given here.

Note: Before carrying out these procedures, install all equipment as

described in this section.

Checking for Proper Blower Rotation

Three-Phase Models

Caution! In three-phase models, incorrect phasing of power leads can cause

backward rotation of blower motors and CONTAMINATION OF THE

DESICCANT!

Always check blower rotation before putting material in the drying hopper!

The blower is rotating properly when air flows from the delivery outlet.

Note: Holding your hand in front of the air return will also indicate if the

blower rotates in the proper direction.

If the three-phase blower rotates improperly, reverse any two wires at the fused disconnect

outside the dryer or at the disconnect/terminal in the control enclosure. This assures that the

blower rotates in the proper direction.

Making Dryer/Drying Hopper Process Air Connections

Floor Mount Models

When making process air connections to your floor mounted dryer, ensure that you take into

consideration and make arrangements for the following:

• Use high-temperature flexible dryer hose or rigid tubing to connect the dryer to the

drying hopper.

• Keep the delivery hose to the drying hopper as short as possible to minimize heat loss.

We strongly recommend insulated hose for maximum energy savings.

• Do not use insulated hose on the return from the drying hopper.

• The return air to the blower must be 150

F (66ºC) or below. If the return air

temperature is not below this point, you should purchase and install the optional

aftercooler to remove excessive heat. Consult the manufacturer for more information.

Aftercooler considerations also apply to machine-mount models.

• Make sure that hoses are not kinked or collapsed.

• Drying hopper air inlet and outlet locations vary, but always connect hoses so the dry

process air from the dryer enters the bottom of the drying hopper and flows out the top

to return to the dryer inlet.

• Thermocouple is to be installed at drying hopper’s delivery tube.

15, 30, & 60 cfm Compact Dryers Chapter 3: Installation 20 of 51

Drying Hopper Air Trap Considerations

Our exclusive air trap assembly on the top of the drying hopper prevents ambient air from

contaminating the material being dried. To ensure that your unit will operate at peak

efficiency, do the following:

• Keep the material level at the mid point of the air trap

This can be achieved by utilizing a hopper loader or vacuum conveying system to

supply material to the drying system.

Optional Aftercooler

Water-cooled 15 and 30 cfm models use a water-to-air heat exchanger as an aftercooler.

Cooling water is required for this design (3 gpm at 85°F or lower). Return air from the

hopper passes through the air filter to trap fines and dust before entering the heat exchanger.

Installing Water Lines

(Hose and Hose Clamp)

When installing the water lines, ensure that the aftercooler utilizes either tower, chilled or city

water up to 85°F (29°C). Recommended flow rate is three (3 gpm) gallons per minute (11

liters per minute).

3-5 Initial Start-up

Pre-Startup Checks

˛ Check the process and return hoses for tight connections.

˛ Check all companion equipment, such as the drying hopper; verify that the loading

system is ready for operation.

˛ Verify that all dryer electrical connections are tight.

Caution! Clean the rust-preventing oil from inside the drying hopper.

Failure to clean the hopper fouls the desiccant and voids your warranty!

˛ Verify that the dryer’s thermocouple is properly connected in the center of the drying

hopper’s delivery tube.

˛ Verify that the temperature control has been configured for your specified scale (ºF

or ºC).

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ACS A0570882 User manual

Brand: ACS

Model: A0570882

Type: User manual

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ACS A0570882 User manual

ACS A0570882 User manual

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